Mardin’s cooler upgrade
Autumn 2014 saw the installation of a new 4000tpd cooler at Mardin Cement, southeastern Turkey. Taking into consideration a limited stoppage time, the project was successfully completed in just 21 days from flame-off to flame-on. The new cooler has cleared a bottleneck in the pyroprocessing line and has enabled the plant to operate at a much higher capacity. By Ugras Akay & Mogens Fons, Fons Technology International, Turkey.
Mardin Cement is part of Turkey’s leading cement producer, the OYAK Group. The Mardin works serves the domestic southeastern region as well as neighbouring countries such as Iraq and Syria. The plant operates two lines, the older of which has a capacity of 2100tpd while the newer line has a design capacity of 4000tpd. However, output of this latter line was being limited to 3400ptd because of the inappropriate design of the clinker cooler mechanics which caused bottlenecks. High cooler loss and heavy mechanical failures resulted in unplanned kiln stoppages. The inefficient cooler process meant the line was operating with a high outlet and vent air temperatures.